Method for Producing a Fastening System, in Particular for Components of Photovoltaic Systems

ABSTRACT

Method for producing a fastening system, in particular for components of photovoltaic systems, preferably on roof surfaces of buildings, in a first step a support surface ( 1 ) being provided, on which at least one fastening component ( 7, 19 ) consisting of loop and/or other interlocking elements is applied and which after fastening the respective fastening component ( 7, 19 ) in the mounted state of the support surface ( 1 ) allows the attachment of at least one other corresponding fastening component ( 7, 19 ) which, provided with other interlocking elements, enables the detachable connection of the assignable fastening components ( 7, 19 ).

The invention relates to a method for producing a fastening system, in particular for components of photovoltaic systems, preferably on roof surfaces of buildings. Furthermore, the invention relates to a fastening system produced according to such a method, and to a support element and a support surface which are intended for use in such a fastening system.

Fastening systems in which touch-and-close connections of complementary interlocking elements which can be engaged to one another are used in order to fasten components, such as solar power components, to support surfaces, especially roof surfaces, are prior art; compare, for example, DE 103 29 184 A1 or WO 2011/076307 A1. In the practical use of such systems, the attachment of the interlocking elements to an attachment surface of the supporting structure, that is to say, a building surface or roof surface, presents no problems only in those cases in which the surface composition of the attachment surface is suitable enough for producing the connection to the interlocking element. In roof surfaces, this is often not the case, for example, when there are concrete surfaces, or rough wood surfaces, or insulating layers. A reliable connection can be produced in such cases at best by using special touch-and-close fastener elements in which there are interlocking elements on a support which is compatible with the respective surface composition of the attachment surface. In ordinary touch-and-close fastener elements with fleece-like, nonwoven-like, or fabric-like backing, this is not the case. The necessity of special selection of the touch-and-close fastener elements to be used and the special measures which must be taken for a reliable attachment of the touch-and-close fastener elements to the attachment surface lead to complication and increased costs in the prior art.

With respect to these problems, the object of the invention is to devise a method for producing a fastening system which enables a simple, reliable, and economical fastening of the corresponding components.

This object is achieved according to the invention by a method having the features specified in claim 1 in its entirety.

Accordingly, the method according to the invention as one important feature calls for a support surface to be provided on which at least one fastening component consisting of loop and/or other interlocking elements is applied and which after fastening the respective fastening component in the mounted state of the support surface allows the attachment of at least one other corresponding fastening component which, provided with other interlocking elements, enables the detachable connection of the assignable fastening components. Regardless of the respective type of the attachment surface or roof surface, on the top of the support surface for attaching the fastening component a suitable joining surface is thus available so that touch-and-close fastener elements of any desired structure can be easily and reliably attached as fastening components.

Especially advantageously, the support surface can be produced from a bitumen mass or from plastic, on at least one surface region of the support surface at least one fastening component being attached, preferably by coating or laminating it on.

When using a plastic support surface, it is preferable to proceed such that the support surface is provided in the form of a thin plastic sheet, preferably of an elastomer material, for example, from a synthetic rubber material or a thermoplastic olefin.

In especially advantageous exemplary embodiments, it is possible to proceed such that to form the support surface, a backing web is provided, for example, in the form of a thin tape of a plastic, such as PET or the like, with the backing web being applied in one transport direction at an application station on which a bitumen mass is applied, preferably by doctoring, and being moved past a following attachment station at which the assigned fastening component is attached in the chosen surface area.

Bitumen layers as are installed as insulating layers on building surfaces or roof surfaces are often provided with an intercalated or attached granulate. When using a bitumen layer to form the support surface according to the method according to the invention, it is possible to proceed in this respect such that the backing web provided with the bitumen mass and with the fastening component is moved past a sprinkling station on which a granulate is applied on the surface regions which are free of the fastening component.

The subject matter of the invention is also a fastening system which has been produced using the method according to the invention and which according to claim 6 is characterized in that the respective fastening component which can be joined to the support surface by interlocking is located on a support element which is designed as a holder for structural elements, especially components of photovoltaic systems.

Especially advantageously, the respective support element can be made in the form of a mounting rail which on the side facing the support surface is provided with the pertinent fastening component in the form of a touch-and-close fastener element. In this connection, the touch-and-close fastener element which is located on the support surface can be provided in the form of at least one tape which extends on the area of the support surface and along the respectively assigned mounting rail.

Especially advantageously, the respective mounting rail can be made in the form of a profile of plastic, for example, an acrylic-nitrile-styrene-acrylate. This type of profile can be extruded in an extrusion process and can be subdivided into longitudinal sections intended for the respective application.

Preferably, the respective profile is made as a hollow profile which has receiving spaces for holding lines or other components of photovoltaic systems which are inserted into them.

Especially advantageously, the respective hollow profile can have wall parts for forming support and/or fastening regions for solar panels.

The mounting rail, especially for the attachment of flexible solar panels, can be made in the form of a profile strip which has at least one longitudinal slot for accommodating the fastening edge of a pertinent solar panel, which edge is inserted into it.

The subject matter of the invention is also a support element for use in a fastening system according to the invention, with the support element according to claim 14 being characterized in that it is made in the form of a mounting rail which has been extruded from a plastic material.

The subject matter of the invention is furthermore also a support surface which is designed for use in the fastening system according to the invention and which according to claim 22 is characterized in that it is formed from a bitumen mass or in the form of a thin plastic sheet, preferably of an elastomer material, on the top of the support surface there being at least one touch-and-close fastener element in a location which is in a positional relationship to an assigned support element which is to be fastened.

The invention is explained below using exemplary embodiments shown in the drawings.

FIG. 1 shows a detached perspective oblique view of one support surface in the form of a bitumen mass with a touch-and-close fastener element located on it as a component of one exemplary embodiment of the fastening system according to the invention;

FIG. 2 shows a side view of what is shown in FIG. 1;

FIG. 3 shows a perspective oblique view of one support surface in the form of an elastomer plastic sheet with a touch-and-close fastener element located on it as a component of another exemplary embodiment of the fastening system according to the invention;

FIG. 4 shows a section according to section line IV-IV from FIG. 3;

FIG. 5 shows a perspective oblique view of a longitudinal section of one exemplary embodiment of a support element as a component of one exemplary embodiment of the fastening system according to the invention;

FIG. 6 shows a cross section of the support element from FIG. 5 with the assigned touch-and-close fastener element located on it;

FIGS. 7 and 8 show a perspective oblique view and a cross section of one exemplary embodiment of a support element which has been modified compared to FIGS. 5 and 6;

FIG. 9 shows a perspective oblique view of a support element similar to FIG. 7 with lines inserted into it;

FIG. 10 shows a cross section of what is shown in FIG. 9;

FIG. 11 shows a perspective oblique view of one modified embodiment of the support element in the form of a profile strip with solar panels fastened on it;

FIG. 12 shows a side view of the profile strip which is drawn enlarged compared to FIG. 11, and

FIG. 13 shows a highly schematically simplified representation of a device for producing a support surface for use in the fastening system according to the invention.

The exemplary embodiment of a support surface 1 shown in FIGS. 1 and 2 is formed by a bitumen web 2 on whose surface 5 a touch-and-close fastener element 7 is fastened. The latter extends in the form of a strip or tape 9 over the top 5 of the web 2 of bitumen mass, with the surface region of the bitumen web 2, which is free of the touch-and-close fastener element 7, being provided with attached granulate 4. The bitumen web 2, which is made to have a much larger area than the touch-and-close fastener element 7, with its underside 11 makes available a correspondingly large-area connecting region for the connection to a corresponding support surface (which is not shown), for example, a roof surface or components thereof.

The tape 9 of the touch-and-close fastener element 7 extends in a positional orientation which is aligned to an assigned support element which is to be anchored on the support surface 1. The respective support element is a mounting rail of which in FIGS. 5 to 10 exemplary embodiments are shown and are designated as a whole as 13, or is a respective profile strip as is shown in FIGS. 10 and 11 and is designated as 16. In FIG. 1, on the support surface 1, there is only one tape 9 of the touch-and-close fastener element 7 for a single support element on the bitumen web 2. In systems with several support elements on a common support surface 1, there can be several tapes 9 with touch-and-close fastener elements 7, or there can be several support surfaces 1 with one tape 9 each, as is shown in FIG. 1.

FIGS. 3 and 4 show a second exemplary embodiment of the support surface 1 in the form of a sheet 3 of an elastomer plastic material, for example, a synthetic rubber or a thermoplastic olefin. As in the exemplary embodiment from FIGS. 1 and 2, a touch-and-close fastener element 7 in the form of a tape 9 on the top 5 of the support surface 1 is attached by coating or laminating it on, as is likewise the case in the example from FIGS. 1 and 2, there being touch-and-close fastener elements which in the known construction can have interlocking elements 21 in the form of mushrooms, loops, or hooks. In the exemplary embodiments provided here, there are interlocking elements 21 in the form of loops in the touch-and-close fastener elements 7 provided on the support surface 1. These touch-and-close fastener elements 7 form a kind of fleece with a base formed by a fabric. With respect to the permeability of the base, in lamination or cementing onto the top 5 of the support surface, for example, of the bitumen web 2, the procedure is such that there is no material passage through the base, for example, by plasticized bitumen, to the region of the interlocking elements 21 in the form of loops.

FIGS. 5 and 6 show a first exemplary embodiment of a mounting rail 13 in the form of a hollow profile 15, which is extruded from a plastic material in an extrusion process. It can be a thermoplastic polymer, for example, acrylic-nitrile-butadiene-styrene (ABS) or preferably an acrylic-nitrile-styrene acrylate. In order to protect parts of the hollow profile 15 which are exposed during use, there can be a sunproof and/or weather-resistant coating at least on outside surfaces of the hollow profile 15. For example, materials such as polymethylmethacrylate (PMMA) or polytetrafluorethylene (PTFE) are suitable for this coating. This coating can be efficiently formed by a coextrusion method in the production of the hollow profile 15.

The hollow profiles 15 on the underside have a flat fastening surface 17 for attaching a touch-and-close fastener element 19 which corresponds to the touch-and-close fastener element 7 of the support surface 1. Like this touch-and-close fastener element 7, the touch-and-close fastener element 19 also has interlocking elements 21 on a backing 23 which on the side of the support surface 1 cements or bonds to the top 5 of the support surface 1 or is laminated onto it and on the side of the hollow profile 15 is cemented or bonded to the fastening surface 17. The touch-and-close fastener elements 7 and 19 can be made in a conventional manner, i.e., they can have conventional interlocking elements 21 in the form of mushrooms, loops, or hooks. In the present exemplary embodiment, the interlocking elements 21 are made on the hollow profile 15 in the form of mushrooms.

Instead of the example which is shown in FIG. 6 and in which the touch-and-close fastener element 19 with its backing 23 is fastened on the fastening surface 17, alternatively, the interlocking elements 21, especially in a version as mushrooms, can also be formed on the fastening surface 17 of the material of the hollow profile 15 itself. On the two end edges of the fastening surface 17 as an edge enclosure, a slightly projecting edge rib 25 is formed as a lateral guide for the respective tape of the touch-and-close fastener element 19 which is located on the fastening surface 17. The hollow profile 15 has, proceeding from the lower fastening surface 17, flat side walls 27 which run slightly converging upward and on the upper end undergo transition into profile webs 29 which extend opposite one another in the plane parallel to the fastening surface 17, but end at a distance from one another. Within the profile shape, inner walls 31 are formed which extend proceeding from the central region of the fastening surface 17 diverging to one another upward toward the profile webs 29 and with the side walls 27 border one receiving space 33 at a time. An intermediate wall 35 which runs in a parallel plane underneath the profile webs 29 between the inside walls 31 borders another triangular space 37 and an overlying space 39 which is open between the profile legs. The flat outside surfaces of the profile legs 29 and the space 39 which forms a type of dovetail guide form a support and attachment region for a pertinent component which is to be fastened (which is not shown), and it can be, for example, a component of a solar power system, for example, a solar panel.

FIGS. 5 and 6 show one exemplary embodiment of the hollow profile in which an overhanging rail 41 is molded on one side wall 27 and forms an open receiving space 43 which can be used, for example, as a cable duct for lines 45 (FIGS. 9 and 10).

FIGS. 7 and 8 show a modified exemplary embodiment of the hollow profile 15 which differs from the example from FIGS. 5 and 6 simply in that the inside walls 31 run at a distance to one another, parallel to one another, and perpendicular to the fastening surface 17, so that space 43 located underneath the intermediate wall 35 has a rectangular cross section.

FIGS. 9 and 10 show one modified exemplary embodiment of the hollow profile 15 from FIGS. 7 and 8 without the laterally attached rail, with one line 45 at a time being inserted into the receiving spaces 33 formed between the side wall 27 and inside wall 31. The hollow profile from FIGS. 9 and 10 and likewise the hollow profile 15 from FIGS. 7 and 8 also differ from the hollow profile 15 according to FIGS. 5 and 6 in that the space 39 open at the top has the cross-sectional shape of a rectangular dovetail guide with wall parts which run perpendicular to one another by the end sections of 47 of the inside walls 31, which sections run parallel to one another.

FIGS. 11 and 12 show one modified embodiment for the mounting rail 13 in the form of an elongated, relatively flat profile strip 16. In the same manner as the hollow profile 15, the profile strip is extruded from a corresponding plastic material in an extrusion process. The strip 16, like the hollow profile 15, on the underside has a flat fastening surface 17 for a touch-and-close fastener element 19. In the central region of the fastening surface 17, from its top 18 a clamping part 20 extends in the longitudinal direction of the strip 16, with the clamping part 20 having a cross-sectional shape in the form of a flat T with lateral clamping wings 22 which border a longitudinal slot 24 between themselves and the top 18 of the fastening surface 17. As FIG. 11 illustrates, a flexible solar panel 26 can be inserted into the respective longitudinal slot 24, with the wings 22 fastening the fastening edge 28 of the solar panel 26 by clamping; see FIG. 11. The solar panel 26 can be an arrangement of solar modules which is located on a backing film which consists of a preferably napped plastic sheet with a rectangular outline. In commercial solar panels of this type, the plastic film supporting the modules has dimensions of about 55×40 cm and consists of a weather-resistant plastic material, such as PMMA or PTFE, with the edge zones 28 which are free of modules being usable as holding regions for fastening of the panels 26.

FIG. 13 shows highly simplified the production of a support surface 1 on a bitumen web 2 which is provided with the assigned touch-and-close fastener element 7 and with attached granulate 4. In the device, a backing web 30 of plastic material such as PTFE is moved in one transport direction marked with arrow 32 past an application station 34 on which a bitumen layer 40 is formed on the transport web 30 from a bitumen mass, a so-called “molasses” 36, by means of a doctor blade 38. The transport web with the formed bitumen layer 40 is moved past an attachment station 42 at which the pertinent touch-and-close fastener element 7 is attached on the top of the bitumen layer 40; as described above, this takes place by cementing it or laminating it on. Then the transport web 30 with the bitumen layer 40 and with the attached tape of the touch-and-close fastener element 7 runs through a drier 44 to a following sprinkling station 46 at which granulate for attachment is scattered in the surface regions which are free of the touch-and-close fastener element 7. The support surface 1 which has been produced in this way can at this point be wound up together with the backing web 30 and transported as a coil to the site of use (such as a construction site) where, after unwinding, the backing web 30 can be removed from the underside of the support surface 1 before its actual use.

One very great advantage of this invention is that in the indicated production method, the loop tape to be applied with its base fabric structure need not be immersed into the bitumen web, but is applied rather almost flush to the top of the bitumen web. If bitumen components penetrate into the base surface of the backing fabric of the loop tape, they allow a strong connection of the loop tape to the base backing material in the form of the bitumen layer without the interlocking capacity of the loop material being adversely affected. This also applies to the case in which the loop surface is replaced by an interlocking layer also in a mushroom form. 

1. A method for producing a fastening system, in particular for components of photovoltaic systems, preferably on roof surfaces of buildings, in a first step a support surface (1) being provided, on which at least one fastening component (7, 19) consisting of loop and/or other interlocking elements (21) is applied and which after fastening the respective fastening component (7, 19) in the mounted state of the support surface (1) allows the attachment of at least one other corresponding fastening component (7, 19) which, provided with other interlocking elements (21), enables the detachable connection of the assignable fastening components (7, 19).
 2. The method according to claim 1, characterized in that the support surface (1) is produced from a bitumen mass (36) or from plastic (3) and that on at least one surface region of the support surface (1) at least one fastening component (7, 19) is attached, preferably by coating or laminating it on.
 3. The method according to claim 2, characterized in that the support surface (1) is provided in the form of a thin plastic sheet (3), preferably of an elastomer material.
 4. The method according to claim 1, characterized in that to form the support surface (1) a backing web (30) is provided which is applied in one transport direction (32) at an application station (34) on which a bitumen mass (36) is applied, preferably by doctoring, and is moved past a following attachment station (42) at which in the chosen surface area the assigned fastening component (7, 19) is attached.
 5. The method according to claim 1, characterized in that the backing web (30) provided with the bitumen mass (36) and the fastening component (7, 19) is moved past a sprinkling station (46) on which a granulate (4) is applied on the surface regions which are free of the fastening component (7, 19).
 6. A fastening system produced according to the method according to claim 1, characterized in that the respective fastening component (19) which can be joined to the support surface (1) by interlocking is located on a support element (13, 16) which is designed as a holder for structural elements, in particular for components (26, 45) of photovoltaic systems.
 7. The fastening system according to claim 6, characterized in that the respective support element is made in the form of a mounting rail (13) which on the side facing the support surface (1) is provided with the pertinent fastening component in the form of a touch-and-close fastener element (19).
 8. The fastening system according to claim 6, characterized in that the respective fastening component in the form of a touch-and-close fastener element (7) assigned to the support surface (1) is made in the form of at least one tape (9) which extends on the surface of the support surface (1) along the respectively assigned mounting rail (13).
 9. The fastening system according to claim 6, characterized in that the touch-and-close fastener elements (7, 19) which form the respective fastening component have a backing (23) with interlocking elements (21) which are located on its one side, which backing is cemented or bonded to the respectively associated mounting rail (13) or the support surface (1).
 10. The fastening system according to claim 6, characterized in that the respective mounting rail (13) is made in the form of a profile (15) of plastic, for example, an acrylic-nitrile-styrene-acrylate.
 11. The fastening system according to claim 6, characterized in that the respective profile is made as a hollow profile (15) which has receiving spaces (33, 37, 43) for holding lines (45) or other components of photovoltaic systems which are inserted into them.
 12. The fastening system according to claim 6, characterized in that the respective hollow profile (15) has wall parts (29) for forming support and/or fastening regions for solar panels.
 13. The fastening system according to claim 6, characterized in that the mounting rail is made in the form of a profile strip (16) which has at least one longitudinal slot (24) for accommodating the fastening edge (28) of a solar panel (26), which edge is inserted into it.
 14. A support element for use in a fastening system according to claim 6, characterized in that it is made in the form of a mounting rail (13) which has been extruded from a plastic material.
 15. The support element according to claim 14, characterized in that the mounting rail (13) in the form of a profile (15) is made with a fastening surface (17) which is located on its underside and on which a pertinent touch-and-close fastener element (19) can be attached or is attached preferably by cementing.
 16. The support element according to claim 14, characterized in that the profile in the form of a hollow profile (15) has at least one receiving space (33, 37, 43) for components (45) of photovoltaic systems.
 17. The support element according to claim 14, characterized in that within the hollow profile (15) there is at least one closed receiving space (33, 37).
 18. The support element according to claim 14, characterized in that on the outside of the hollow profile (15) there is at least one open receiving space (43), preferably in the form of a cable duct.
 19. The support element according to claim 14, characterized in that the hollow profile (15) has side walls (31) which run from the lower flat fastening surface (17) converging upward and whose upper ends adjoin profile webs (29) which form a support or attachment region for a component such as a solar panel.
 20. The support element according to claim 14, characterized in that closed receiving spaces (33, 37) of triangular or rectangular cross section are formed within the hollow profile (15).
 21. The support element according to claim 14, characterized in that it is shaped in the form of a strip (16) which has at least one longitudinal slot (24) for accommodating the fastening edge (28) of a solar panel (26), which edge is inserted into it.
 22. A support surface for use in a fastening system according to claim 6, characterized in that it is formed from a bitumen mass (2, 36) or in the form of a thin sheet (3) of plastic, preferably of an elastomer material, and that on the top (5) of the support surface (1) there is at least one touch-and-close fastener element (7) in a location which is in a positional relationship to one assigned support element (13, 16) which is to be fastened.
 23. The support surface according to claim 22, characterized in that the pertinent touch-and-close fastener element (7) is made in the form of at least one tape (9) which is located within the surface of the top (5) of the support surface (1) and which extends along one respectively assigned mounting rail (13) or strip (16) which is provided as the holding element. 